Static structures (e.g. – buildings) – Opaque stonelike module – Particularly related to adjacent module
Reexamination Certificate
1999-05-06
2001-03-27
Kent, Christopher T. (Department: 3635)
Static structures (e.g., buildings)
Opaque stonelike module
Particularly related to adjacent module
C052S421000, C052S439000, C052S574000, C052S592100, C052S596000, C052S607000, C052S608000
Reexamination Certificate
active
06205735
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to unit-shaped masonry blocks, and more specifically to dry-stackable masonry unit configurations and methods of erecting dry-stackable masonry unit structures.
2. Description of the Prior Art
Masonry construction blocks and methods for constructing various kinds of brick or block walls are well known in the art. Because of the difficulty and high cost of constructing walls of quarried stone or block, cast cementitious blocks long ago replaced quarried stone as a preferred material in many applications.
Cast blocks typically have a uniform size and shape, include at least one cavity, and frequently permit physical interlocking, either vertically or horizontally, with integrally formed or independent connection means. Such interlocking designs facilitate rapid assembly and proper alignment during fabrication. They also permit assembly without mortar, so that some designs of cast blocks may be employed for temporary walls that can be easily disassembled.
Walls constructed of cast blocks may rely exclusively on the mass of the blocks to maintain alignment and stability. However, mortarless cementitious cast block walls intended for permanent use usually require additional stability. Accordingly, many designs permit mortar or reinforced concrete to be poured or injected into and to fill gaps and aligned vertical and horizontal openings in the blocks.
However, along with their advantages, the known cast blocks also have many disadvantages, including: difficulty in converting the wall units into end or corner units; lateral instability; vulnerability of exposed mortar to chemical or environmental degradation; expansion and contraction of mortar, causing cracking and separation of blocks; difficulty in constructing curved configurations; and vulnerability of broad flat surfaces to defacement and graffiti.
SUMMARY OF THE INVENTION
The present invention is a mason wall cementitious building block system comprising two lightweight dry-stackable block units and methods of using such units. The blocks include a wall unit and a corner/end unit, and corresponding variations on each to function as cap units. Adjoining wall units and corner/end units connected one to another in an interlocking fashion. Caps for each of these units interconnect with adjoining caps via ends of staggered lengths. The unit shapes, the methods of assembling walls of such units, and the walls constructed of such units, overcome the limitations of the prior art.
The wall unit of the present invention comprises a front face, a rear face, an upper face, a lower face, two sides, two male posts projecting from said sides, and two female sockets integrally formed in said sides. In a preferred embodiment, two holes extend vertically through the block for engagement with raised stops on blocks of inverted position stacked either below or above. The male posts angle back from the front face towards the rear face and terminate in a rounded enlarged head for interconnection with the female socket of an adjoining block. Each rearwardly angled male post defines a partial aperture at the side of the block, such that interconnected adjoining blocks in an assembled wall define an aperture which extends vertically between the adjoined blocks for placement of vertical reinforcement rebar, the introduction of mortar or cement, and plumbing and electrical chase, as needed. The top face defines a shallow recess located in approximately the middle of the block and running the length of the block essentially parallel to the front and rear faces.
The corner/end unit of the present invention comprises an end face, one male post, one defined female socket, and a potential female socket defined by an interior cylindrical aperture extending vertically through the block. This unit may function as either an end or a corner, requiring only the removal of a small portion of the block at prescored cut lines for use as a corner.
The wall cap unit comprises outer faces, two sides with a short projection extending from and a short recess extending into opposite sides of partial arcuate apertures at each side, a bottom surface, and a recess extending into the top bed face and running along its entire length generally parallel to the outer faces. The upper portion of the outer face is decoratively beveled. Corner caps have the same structure as wall caps, but with a right angle introduced at the longitudinal midpoint. The end cap unit is essentially a truncated wall cap unit with a single partial aperture, an end face, and a recess extending into the top bed face that terminates short of the interior border of the end face.
A method of erecting structures comprised of the above-described units comprising the steps of:
1. Forming a poured-in-place concrete footing with embedded vertical reinforcement;
2. Stacking a plurality of courses of block as described above in running bond, stepped, or stacked bond layouts with the male posts of blocks interconnected with the female sockets of adjoining blocks to align and fix the blocks in position and to define a vertical aperture between adjoining blocks for placement of the vertical reinforcement and selected electrical and plumbing chase;
4. Laying horizontal rebar in the aperture defined by one course overlying another;
5. Placing a post tension clamp over the vertical rebar until it nests on horizontal rebar and tightening the clamp to cut into vertical rebars;
6. In the case of permanent walls, pouring mortar or concrete into at least some of the vertical apertures to flow through said apertures and into horizontal apertures to form a continuous joint between adjoining blocks, leaving the front and rear faces exposed.
REFERENCES:
patent: 2290369 (1942-07-01), Fleischmann
patent: 3557505 (1971-01-01), Kaul
patent: 5315802 (1994-05-01), Hart
patent: 5337527 (1994-08-01), Wagenaar
patent: 5941042 (1999-08-01), Dueck
patent: 5951210 (1999-09-01), Maguire et al.
Pieter VanderWerf, Mortarless Block Systems, Feb. 1999, Masonry Construction, p. No. 20-24.
Johnson Larry D.
Johnson & StainbrookLL
Kent Christopher T.
Stainbrook Craig M.
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